Metallurgical process.



' M. MOORE & T. J. HESKETT. METALLURGICAL PROGESS.

APPLICATION FILED APR. 17, 1908.

Patented June 7,1910.

2 SHEETS-SHEET 1.

Warz Zjgyme 74730 awe Mr M mamds amema M. MOORE & T. J. HESKET T. METALLURGICAL rnoonss.

' 7 APPLICATION FILED APB.17, 1908. 960,987" Patented June 7,1910.

-2 sums-sum 2.

azz'z666e6/ i Jive/2am 7/fazzym 7/( re r 7 1270mm Medfles 26w v PEN UITEI) earns nnsxnr'r, or nrwnswrcx,

METALLURGICAL PROCESS.

Speeificationbf Letters Iatent.

.Patented am a, into.

Application filed April 17, 1908. Serial No. 427,755.

To all whom 'it may concern:

Be it known that we, MONTAGUE Moons and Tnonms J AMES Hnsnnrr, subjects of the King of Great Britain, residing at No. 314 Collins street, Melbourne, in the State of Victoria and Commonwealth. of Australia, and N0. 2 Donald street, Brunswick, in the said State, respectively, have invented certain new and useful Improvements in Metallurgical Processes, of which the following is a specification.

This invention relates to improvements on what is known as the Moore-Heskett process for treating ferruginous ore for the manufacture of iron and steel therefrom. According to the said process the ore is first ground or crushed to a fine state of division, the silica earthy or other deleterious matter being concentrated and separated therefrom. The oreis then subjected while passing through a chamber to heat, preferably produced by the admixture of air with waste carbonic oxid or hydro-carbon gas issuing from another chamber, and then to the progressive reducing action of such gas or gases alone while passing through said latter chamber, and 1s thenpassed without coming in contact with an oxidizing atmosphere into a Siemens or other gas furnace where it is fused and balled up as wrought iron or converted into steel.

The apparatus used in carrying out the said process consists essentially either of a the reducing gas downward.

vertical tower, which ractically constitutes two chambers, a revo ving cylinder and a vertical tower, or two revolving cylinders, and a Siemens gas furnace in communication with the bottom of the tower or the second and lowermost of the two revolving cylinders. The gases used for both heating and reducing pass either upward in the opposite direction to the ore being treated, or the gas for heating passes upward and In the latter case the reduced ore is delivered to the gas furnace and beneath a bath of m'olten 'metal therein, while enveloped or protected from oxidation by the reducing gas which is fed in wit-h it, but we find that said reducing gas by the time it reaches the entrance to the gas furnace has become so deteriorated bythe admixture therewith of oxygen given off from the ore that the best results are not Obtained.

Now according to our present invention chamber to the up into wrought iron, and subsequently taken out through the doors to a squeezer or hammer and treated in the ordinary way for the production of wrought iron bars &-c. The waste gases from the gas furnace pass upward to an air regenerator to heat the air passing therethrough to the gas furnace.

To make and maintain thebath of slag in the gas furnace and to melt any silicious or earthy materials adhering to the ore, fluxes may be supplied through the door of the gas furnace, or may be delivered with the ore from the reducing chamber.

hen steel is to be manufactured scrap steel or wrought iron is melted with solid fuel in a cupola furnace, by which means it becomes highly carburized, and is fed into the gas furnace into which the reduced iron falls. A high temperature is maintained in the furnace, and consequently the reduced iron is speedily melted, and when the bath is full of metal in a state of fluidity the whole or part of the metal is tapped out or run into a refining furnace. The bath of metal in the refining furnace contains a minimum ofslag and alloyed carbon and in saidrefinin furnace can be quickly refined and treated in the ordinary way to obtain a metal of exact quality and without interfering with the continuous melting of the reduced iron in the gas furnace. Any required alloys are added to the metal and the bath may be of an acid or basic character to suit the metal under treatment. When ready, the metal is poured into ingot molds in the usual way.

In carrying out the process above described we provide an inlet for the reducing gas at the bottom of the reducing chamber, an air inlet at the bottom of the heating chamber, and a damper at the top of the latter chamber. By means of said damper p 5 riod.

the volume of gas entering near the bottom of said reducing chamber can be so controlled as that a portion thereof will pass throug said reducing chamber while the re- 5 maind r will pass with the reduced metal to the g s furnace. In cases where a tower is use for heating and reducing the iron ore, or in conjunction with a revolving cylinder for the same purposes, we prefer to construct said tower in the same way as an ordiintimate contact between the ore and gases.

In communication with the gas furnace into which the reduced metallic iron is continuously fed are one or more cupola melting furnaces, in which scrap steel or wrought iron can be melted with solid fuel and poured into the bath of the gas furnace when required. A launder leads from said gas furnace to another gas furnace constitutin a refining furnace and through this laun er the metal runs into said refining furnace. If preferred,- the metal can be tapped into the refining furnace as required. As has been before explained, the cupola furnaces and also the refining furnace are not used when making wrought iron, they only being necessary in the manufacture of V steel, but if it is required to make a more or less steely quality of wrought iron, the highly carburized metalin the cupola furnacemay be run into the gas melting furnace. A lower tem erature in that case is maintained in the mace so that the reduced iron does not melt but is balled up in the usual way for wrought iron, in a 5 bath of carburized iron and slag.

In cases where ore rich in iron is procurable and concentration is therefore not necessary we treat'it in lump form thus avoiding the expense of crushing to a fine state of division. When lump ore is treated the heating and reducing chambers are not rovided with means to delay the passage of the ore as in the case of ore in a fine state of division; The heating and reducing chambers are simply filled with the ore to be treated, and the bottom of the reducing chamber is slightly altered in construction so that the ore remains at rest, say upon a shelf, until it is either drawn forward by (30 hand into the bath or pushed forward by mechanical means.

Referring to the drawings hereto annexed Figure 1 is a plan in section of the apparatus we have devised for carrying our rocess 5 into effect and which forms the sub ect of an application for Letters Patent filed contemporaneously herewith, while Fig. 2 is a sectional elevation on line a b Fig. 1.

A A A A are the heating and reducin chambers which as shown consist of vertica towers, but as previously explained, said heating and reducing chambers may each consist of a vertical tower and a revolving cylinder set at an angle to and in communication with said tower, or two revolving cylinders in communication with each other,

the one constituting the reducing chamber bein at a lower elevation than the other or heatin chamber. The upper portion A of each 0 the towers A constitutes the heating chamber and the lower portion A the reducing chamber. The interior of all these vertical towers may be constructed as shown in Fig. 2 in the same way as an ordinary Siemens regenerator and when so constructed are intended for treating ore in a fine state of division. By so constructing said towers the ore under treatment is com pelled to follow acircuitous courseand its passage through the towers is considerably delayed so as to give the gases suflicient tlme to act on'the ore. If the towers are intended for treating lump ore the internal construction constituting a series of passages is dispensed with.

B is a gas producer and B a feeding door thereto. C is a flue in communication with saidgas Eroducer B, and from which flue G the gas ows through pipes D linedwith fire resisting material to the bottom of the reducing chamber A of each tower A.

A is a passage through which the reduced ore passes to the gas furnace E.

F is an air inlet to the heating chamber A of the tower A.

G'is a flue for the escape ofwaste gas from the top of the heating chamber A, and G is a damper in said flue G by operatmg which the gas supplied to the bottom of the reducing chamber A may be so manipulated as that portion of it passes upward through the reducin and heating chambers A and A while t e remainder passes downward with the reduced ore from reducing chamber A through passage A leadin from the bot tom of each reducing cham r to the gas furnace E.

H is a hopper through which the ore to,

I is an air regenerator. I are cold air in lets to said air regenerator.

I are waste heat fiues leading from the gas furnace E to the air re enerator I. v

I are hot air passages eading from the air regenerator I to the gas furnace E.

I is a waste heat flue at the top of the regenerator I.

J are cupola furnaces and J are launders through which the fluid hi hly carburized metal passes from said cupola furnaces into the bath in the gas furnace E.

E is the flux-charging door to furnace E and E are the working doors of said furnace. a 1

K is a refining furnace and K a launder leading from metal tapping holes E and E to said refining furnace K. K is a metal tappin hole in said refining furnace and K a fee ing door for fuel thereto.

By our apparatus a continuous melting and refining of the ore can be carried on. What .we claim as our invention, and desire to secure by Letters Patent, is

1. The herein described process which consists in introducing a reducing gas into the lower portion of a mass of ore, forming a molten bath below said ore mass and causing a portion of such gas to pass upwardly through the ore while another portion of such gas asses with reduced ore to the molten bat said gas protecting the reduced ore from oxidation until delivered beneath said bath.

is desired.

3. The herein described process which consists in introducing a reducing gas into the lower portion of a mass of ore to cause reduction thereof, melting the reduced ore to form a bath of molten metal, and causing reducin gas to pass with the reduced ore to such bath, melting scrap steel or wrought iron with solid fuel, and conducting such molten metal to said bath, and withdrawing the molten mass from said bath and refining it.

In testimon; set our hands in presence of two subscribing witnesses.

MONTAGUE MOORE. THOMAS JAMES HESKETT.

Witnesses:

WALTER S. BAYsToN, FRANK BAYSTON.

whereof we have hereunto 

